Mr. Malone has over 30 years experience with a major chemical facility that was built in the early 1930s. He was a principle developer and implementer of the company’s mechanical integrity program, which started in the early 90s. In the late 90s, when Risked Based Inspection (RBI) was in its infancy, Mr. Malone led in the revolutionizing of asset management by applying Risk Management concepts within the core businesses strategies of the company.
Mr. Malone is highly skilled in the application of industry codes and standards, such as the American Society of Mechanical Engineers (ASME) (e.g., ASME B31.3, B16.5, Sections V & IX), the American Petroleum Institute’s (API) (e.g., API570, 574, 571, 579, 580, and 581), and the use of data management systems such as Meridium, Vision, PSMS, and Owner User Systems.
Mr. Malone also developed and then directed the piping integrity management system at the Eastman facility into a world class inspection program, utilizing the specialized skills of metallurgist, process engineers, and highly trained inspectors. This program proved to be highly effective for good utilization of man-hours with superior results. He is experienced in all phases of project development and implementation with an eye on the bottom line as a past owner/user.
EXPERIENCE
- Development and Management (Eastman Chemical, TN – Piping)
- Mechanical Integrity Program
- RBI and Analysis Program
- Data Management and Analysis Program
- Assessment Evergreen Program
- Inspection Planning/Execution Program
- Q/A of Nondestructive Testing Group, Techniques, and Functions
- Methodologies for Mechanical Failure Diagnostics and Analysis
- Diagnostics for Data Analysis and Forensic
- Fitness-for-Service and Life Expectancy Assessments Using Corrosion Data and Trending Techniques.
- Enhanced Safe Equipment Operation Using Consequence Mitigation Techniques Based on Failure Modes and Analysis.
- Reliability of Assets Within Windows of Opportunity (Shutdown Planning)
- Manager of Contract Services Regarding Inspection and RBI Services
- Led In-service Damage and Solution Assessment (Eastman Chemical, TN)
- Hydrogen Grooving in Sulfuric Acid Processes
- Erosion/Corrosion Effects in Waste/Fuel Gas Process
- Corrosion Under Insulation (CUI) of Brine Process
- Caustic Cracking of Steam Condensate Process
- Erosion/Corrosion in Boiler Feed Water Process
- Stress Corrosion Cracking in Gasification facility
- RBI assessment and inspection planning for a Pamolyn Process (Eastman, Franklin VA.)
- Inspection Planning for Tall Oil Process (Eastman, Franklin VA)
- Reliability assessments and solutions to improve operations of chemicals
Materials Handling Organization
- RBI Analysis and Inspection Planning (Huntsman Chemical, TX)
- Corrosion Mapping, Assessments, and Inspection Planning of equipment and piping within a Hydrocracker Process (OPTI Refinery, Canada)
- Equipment RBI Assessment and Inspection Planning (Nova Chemical – Canada)
- Development of Engineering Standards Training Modules. (Eastman, TN)
- Training of Maintenance Division Employee’s (approximately 550 employees) in the understanding and application of Piping and Instrument Drawings (P&IDs) and Piping Standards using both Site and Process Industry Practices (PIP) standards. (Eastman, TN)
- Development and management of “Temporary Repair Solutions/Processes” for in-service piping and equipment
- Provided continuous development and support for both local and corporate efforts in the effective functionality and use of the corporate asset management system. (Developed and maintained in the Meridium database environment) (Eastman, TN)
EDUCATION AND PROFESSIONAL BACKGROUND
- Associates Degree, Mech Eng Technology, National Institute for Certification in Engineering Technologies
- License, Eastman Technician Qualified (3/19/2001)
- License, API 570 Authorized Piping Inspector (2/10/2003) „ Liquid Penetrant Testing Level II — ASNT Central Certification Program
- Visual and Optical Testing Level II — ASNT Central Certification Program
- Direct Ultrasonic Thickness Certification — Owner User
- Radiographic Testing Level II Interpretation — Plumstead Qualification Services
- ASME B31.3 Process Piping — Sperko Engineering Services, Inc
- Maintenance Inspection and Mechanical Integrity — Acuren Inspection Inc
- Welding certifications in 20 plus procedures ranging from high and low temp
carbon steels, stainless steels, nickel alloys, and titanium.
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